Multi-stage solenoid actuator and method for operation of a multi-stage solenoid actuator

Abstract

Methods and systems are provided for a multi-stage solenoid actuator. In one example, a system may include a solenoid actuator comprising a series of coils, the first coil enclosed by a first housing, the second and third coils enclosed by a second housing, and a plunger enclosed by the second housing. The method may include the first and second housing, and the plunger, moving in series, increasing the total displace of the actuator via single electric signal.

The invention claimed is: 
     
       1. A solenoid actuator, comprising;
 a first coil; 
 a second coil; and 
 a controller including non-transitory instructions stored in memory that cause the controller to apply a voltage to the first coil and draw the second coil toward the first coil, and then increase modulation of the voltage with the second coil engaged with the first coil to form a transformer. 
 
     
     
       2. The solenoid actuator of  claim 1 , further comprising a first housing coupled to the first coil, and a second housing coupled to the second coil, the first housing movable relative to the second housing. 
     
     
       3. The solenoid actuator of  claim 2 , further comprising a third coil fixedly coupled to the second coil. 
     
     
       4. The solenoid actuator of  claim 3 , further comprising a plunger coupled with the second housing, and a spring coupled between the plunger and the first housing. 
     
     
       5. The solenoid actuator of  claim 1 , wherein the voltage applied to the first coil to draw the second coil toward the first coil is unmodulated. 
     
     
       6. The solenoid actuator of  claim 4 , wherein the voltage applied to the first coil with the first coil engaged with the second coil is modulated at a first higher peak voltage to draw the plunger toward the first coil and the second coil, and then modulated at a second, lower peak voltage to hold the plunger after it is drawn toward the first coil and the second coil. 
     
     
       7. The solenoid actuator of  claim 1 , further comprising a switching device coupled to the first coil. 
     
     
       8. A method of adjusting a solenoid actuator position of a solenoid actuator between a first position and a second position, the solenoid actuator having a first coil and a second coil, comprising:
 applying a DC voltage to the first coil to draw the second coil toward the first coil; 
 after the second coil is in direct contact with the first coil to form a transformer, applying an AC voltage to the first coil to generate current in a third coil that moves a plunger. 
 
     
     
       9. The method of  claim 8  further comprising, after moving the plunger, applying a lower AC voltage to the first coil to generate lower current in the third coil that holds the plunger. 
     
     
       10. The method of  claim 9  further comprising switching from the DC voltage to the AC voltage based on a first threshold position of the plunger. 
     
     
       11. The method of  claim 9  further comprising switching from the DC voltage to the AC voltage based on a first delay. 
     
     
       12. The method of  claim 9  further comprising switching from the AC voltage to the lower AC voltage based on a second threshold position of the plunger. 
     
     
       13. The method of  claim 9  further comprising switching from the AC voltage to the lower AC voltage based on a second delay. 
     
     
       14. The method of  claim 9  further comprising switching from the AC voltage to the lower AC voltage based on a third delay. 
     
     
       15. The method of  claim 9  further comprising during a first mode, adjusting an amount of the DC voltage based on plunger position to achieve a desired plunger position; and during a second mode, adjusting an amount of the AC voltage based on plunger position to achieve the desired plunger position. 
     
     
       16. A method of adjusting a solenoid actuator position of a solenoid actuator between a first position and a second position, the solenoid actuator having a first coil and a second coil, comprising:
 applying a DC voltage to the first coil to draw the second coil toward the first coil against a bias; 
 after the second coil is in direct contact with the first coil to form a transformer, applying an AC voltage to the first coil to generate current in a third coil that moves a plunger further against the bias; and after moving the plunger, applying a lower AC voltage to the first coil to generate lower current in the third coil that holds the plunger. 
 
     
     
       17. The method of  claim 16  further comprising switching from the DC voltage to the AC voltage based on a first threshold position of the plunger. 
     
     
       18. The method of  claim 17  further comprising switching from the DC voltage to the AC voltage based on a first delay. 
     
     
       19. The method of  claim 18  further comprising switching from the AC voltage to the lower AC voltage based on a second threshold position of the plunger. 
     
     
       20. The method of  claim 19  further comprising switching from the AC voltage to the lower AC voltage based on a second delay.